Textile material and method and apparatus for making same



G. BLQCH July 14, 1942.

TEXTILE MATERIALS AND METHOD AND APPARATUS FOR MAKING SAME 3 Sheets-Sheet l INIVENTOR BY WJTW Filed Aug. 16, 1938 July 14, 1942. BLOC-H I 2,289,568

TEXTILE MATERIALS AND METHOD AND APPARATUS FOR MAKING SAME Filed Aug. 16, 1938- 3 Sheets-Sheet 2 lNVENTOR K 7 W ATTORNEYS G. BLOCH July 14, 1942.

TEX' I'ILE MATERIALSYAND METHOD AND APPARATUS FOR MAKING SAME Filed Aug. 16, 1938 s sheets-sheet 5 INVENTOR K W I ATTORNEYS Patented uly 14,. 1942 OFFICE TEXTILE MATERIAL AND METHOD AND APPARATUS FOR MAKING SAME v Godfrey Bloch, New York, N. Y. Application August 16, 1938, Serial No; 225,153

v 8 Claims.

This invention relates to fabric-making materials and more especially to synthetic textile filaments and yarns composed of cellulose, cellulose acetate, ethyl cellulose, benzyl cellulose, glass, resinor any other material adaptable for the production of synthetic filaments.

An object of this invention is to provide synthetic filaments and yarns having characteristics rendering them useful in the textile industry and also to produce such filaments and yarns in a novel and expeditious manner.

Yarns embodying this invention are composed of overlapping filamentary members ranging in length between about one-fourth inch and about ten inches combined with or surrounded by filaments extending continuously the full length of theyarns. The filamentary members may be sections cut from continuous filaments or sections of continuous filaments folded into overlapping relation. Either form of overlapping fila-' mentary members may also be used by itself in the production of yarns. Such yarns from filamentary members of the first type are spun without recourse to carding while yarns from filamentary members of the second type are produced without having recourse to cutting, carding or spinning, although exhibiting some characteristic advantages of yarn produced by these processes. I

[In the production of yarns containing the first 30 type of filamentary members, filaments emergin from a spinnerette or drawn from a cone are cut by groups into desired length in overlapping relation and are introduced into the space between a plurality of moving continuous filaments being spun, after which the resulting combination is gathered into yarn and subjected to any further desired treatment. In the production of yarns containing the second type of filamentary members, continuous filaments in groups are laid in or by combining several groups with more or less twist, either individually or in plying. An ultrasimple embodiment of such yarn would consist of two large mono filaments folded and twisted. However, a more usual embodiment would be several groups of folded filaments twisted together. Yarn composed of folded filaments unless especially made fancy, are of substantially uniform cross-section throughout their entire length due to the fact that there is no set arrangement of folds. and the folds in one group oifset unevennesses in the folds of another group to yield the same average cross-section throughout. The filaments composing such yarns are substantially greater in length than the overall length of the yarn and if such yarns be subjected to draft, a bulging of the folds will result with consequent increasein diameter and protrusions. Any desired degree of twist may be given to the yarn or it may be used in untwisted form and is adapted for many different types of use.

Other objects, novel features and advantages.

of this invention will become apparent from the following specification and accompanying drawings, wherein:

Figure 1 is a schematic illustration of apparatus' for producing yarn embodying the invene tion;

Fig. 2 is a vertical section through filament cutting means;

Fig. 3 is a section on the line -33 of Fig. 2;

Fig. 4 is a section substantially on the line 44 of'Fig. 2; l I

Fig. 5 is a bottom view of Fig. 2, partially broken away;

first type by subjecting the same to the drafting rectly from filamentary members of the second type merely by twisting a group of such filaments Fig. 6 is a section on the line 6-6 of Fig. 2; Fig. 7 is a vertical section through filamentfolding means;

Fig. 8 is a section substantially on the line 8-8 40 of Fig. '7; Fig. 9 is a diagrammatic side elevation of Fig. 7;

Fig. 10 is an' elevation of a detail of Fig. '7;v

Figs. 11, 12, 13 and 14 illustrate modifications; and

Figs. 15 and 16 illustrate yarns embodying the invention.

Referring now more especially to Fig. 1, Ill 15 the tube of a dry spinning apparatus of which there are a plurality but only two'are here illustrated for simplicity sake. In the top of each tube II is located a spinner-otte to which hquid material is supplied through the pipe 12. The filaments I produced by the spinnerette pass out of the bottom of the tube I or imd collecting and guide rollers i3 and 14 and if over a guide roller l5. From the guide roller IS, the filaments from each spinnerette are supplied to a head 16 head I6 is illustrated as being equipped to handle six groups of filaments, although it may be equipped to handle fewer or more groups. If it is desired to use filaments f of more than one type of material, different composition liquids may be supplied to the different spinnerettes. In the production of comparatively large filaments, all but one of the chambers l may be dispensed with and the filaments from a single spinnerette may be divided into six groups and supplied to the head It. Such spinnerette will usually be especially designed for such divisibility, or may be a multiple spinnerette. In the case of the smaller size filaments, or where height is not objected to, a plurality of spinnerettes 21 or a special or multiple spinnerette may be so arranged as to be directly above the head It and filaments are fed directly into the head as shown in Fig. 13, the liquid being supplied by a pipe 22.

In Figs. 2 to 6 is illustrated the form of head used for the production of filamentary members of the first type. Six guide members 25 are provided to direct the groups of filaments f to six pairs of feed rollers 25 provided with suitable gearing for effecting rotation thereof by means omitted for the sake of cleamess. Below the body 23 is provided a gathering and feeding mechanism comprising a first pair of rollers 21 and a second pair of rollers 28 arranged at right angles to the first pair of rollers. The rollers 21 are journalled in a block 29 and the rollers 28 are journalled in a block 30 fixedly supported in a casing 3|. Between the blocks 29 and 30 is arranged a disk 32 having a plurality of holes in which are received balls 33. The disk 32 is pro-- vided with teeth 34 by means of which the disk may be rotated through the medium of suitable gears (not shown). with a friction wheel 35 and each roller 28 is provided with a friction wheel 35, such friction wheels engaging the disk 32 whereby rotation of the disk causes rotation of the rollers.

Centrally of the body 23 is journalled a shaft 31 provided with a fiange 38 equipped with a crank pin 39 by which rotation of the shaft 31 is effected. A shaft 40 is journalled in the shaft 31 eccentrically thereof and carries at its upper end a Each roller 21 is provided pinion 4!. The socket in which the flange 38 is arranged is provided with teeth to constitute a ring gear 42 and gears 43 mounted on the flange 38 constitute a train of gears connecting-the pinion 4| to the ring gear 42; the arrangement being such that the shaft 48 is rotated in the opposite direction to the shaft 31 at six times the speed of the shaft 31. A knife 44 is carried by the' lower end of'the shaft 40 and a knife 45 is carried by the lower end of the shaft 31. The knife blades 44 and 45 are brought into severing relarelationship. By reason of the fact that the shaft 40 is eccentric of the shaft 31, the knife 44 during each revolution clears all the filament groups except theone which is being severed.

The six groups of filaments f are respectively fed by the feed rollers 26 in position to be severed by the blades 44 and 45. The severed groups are confined and fed downwardly by the rollers 21 and 28 through the bore of the annular spinnerette l1 and subsequently are combined with the filaments Any desired degree of twist may be given to the severed groups by rotation of the casing 3| by suitable means (not shown). By operation of the apparatus above described, the groups of filamentary members are combined with the filaments f to form a yarn containing filamentary members in lengthwise overlapping groups combined with continuous filaments. Few or many filamentary members may fuse with the continuous filaments if contact be made while some of the material is still plastic.

In Figs. 7 to 10 inclusive is illustrated the form of head usedfor the production of filamentary members of the second type. Referring more especially to Figure 7, a bushing 48 is journalled in a frame 41 and means not shown are provided for rotating said bushing. In an eccentric bore in the bushing 48 is arranged a sleeve 46 which is held against rotation by suitable means not shown. At its lower end the sleeve carries a spider 48 by which are rotatably supported pairs of intergeared feed rollers 50, one roller of each pair being provided at its inner end with a spur gear 5| meshing with a master gear 5la carried by a hollow shaft 52 journalled in the sleeve 48. Guideways 53 are provided in a flange extending outwardly from the frame 41, there being a guideway for each pair of rollers. Rotation of the bushing 48 causes the sleeve 46 and the associated rollers 50 to traverse a circular orbit and rotation of the shaft 52 by means not shown causes rotation of the rollers to draw filaments through the guideways 53 and feed such filaments downwardly.

The filaments from the pairs of rollers are laid into the bites of two endless bands 54 pass ing over rollers 55 and 55a supported by the body 58, there being a set of bands for each pair of rollers. The rollers 55 are intergeared at their outer ends and one roller of each pair has at its inner end a gear 51 which meshes with a master gear 58 carried by a shaft 59 rotated by means not shown. Because of the circular motion of the spider, the filaments are laid into the bites of the bands circularly, this being permitted by the fact that the filament is fed faster than the bands are designed to carry it away. The bands are angularly related to each other as shown in Fig. 10 so that as the group of filaments passes through the bands, it is slightly twisted or rolled to effect folding of the filaments and to make the group of substantially circular cross-section. Filaments f are supplied to the guides 53 in six groups as illustrated in Fig. 1 and the folded filaments are gathered and confined by rollers .21 and 28 which are supported in a casing 31 and rotated as previously described in connection with Fig. 2. Each group of filaments is normally subjected to the same conditions as every other group. The gathered folded filaments are delivered through the aperture of the annular spinnerette 11 of Fig. 1 and are enclosed by continuous filaments j as previously described to form a yarn containing staggered filamentary members in lengthwise overlapping groups enclosed by filaments extending continuously the full length of the yarn. The filaments f are spun at sufiiciently lower-speed rate than the filaments f, so that the folded filaments and the continuous filaments are advancing at the'same rate when brought into combination. The gathered folded filaments are rolled or twisted by rotation or oscillation of the casing 3|. the exact arrangement illustrated in Figs. 7 to 10, but may be so arranged that they are offset in the direction of belt travel so that the filaments are laid on one belt and are carried thereby a short distance before being gripped between both belts. In such arrangement one belt 54 will protrude beyond the other. I v

In Fig. 11 is illustrated a modified form of gathering and folding means. In this modifiestion, a plurality of stationary guides ill are supported by a rod 6! or the like. Below each guide is arranged a gathering and compressing member comprising a casing 62 rotatable about a vertical The rollers '55 need not be in.

axis fiset from the guide 60 and means (not shown) are provided for rotating or oscillating it. The casing 62 contains two pairs of rollers having the same arrangement and driving means as described in connection with the casing 3|. Filaments are fed throughthe guides at a higher rate than the rolls in casing 62 will take them away, with the result that, due to rotation or oscillation of the casing'62, the filaments are laid in loops which, when passed through the rolls, are folded as previously described. .The folded filaments discharged from the casing 62 are delivered to a single gathering and draft device 64 which has the same internal structure as the casing 62 and is provided with means (not shown) for effecting rotation or oscillation therei of. The gathered combination of filaments may be given any .desired degree of twist or rolling by regulation of the oscillation or rotation of the device '64. If desired, the casing 62 may be made stationary and the rod 6| caused to describe an orbit by suitable means to lay ,the filaments in loops.

The device illustrated in Fig. 12 consists of a casing 66 rotatable or oscillatable by means (not shown) and having the same internal structure as the casing 3i. Two (or more) groups of filaments ,1 are fed to the device 56 at different rates of speed, such that one group is overfed to form loops and the other group is under tension. Such relation may be continuously maintained or each group may be alternately overfed and under tension while the other is subject to the opposite condition. The group of filaments which is overfed is folded as previously described. The device of Fig. 12 may, if desired, be used in multiple and the products from the several devices combined by use of a gathering and draft device such as 64 of Fig. 11. p

In the production of yarn by folding filaments, the filaments may break at their folding points, particularly if the filaments are of brittle structure such, for example, as glass. Also, if desired,

' filaments may be purposely broken at the folding point by any suitable means. Apparatus for breaking the filaments at the folding point is illustrated in Fig. 14. In this figure, filaments out combination with the continuous filaments. The filamentary members of the first type may be spun into yarn along the general procedure followed in the production of yarn from staple rayon by use of further sets of drafting rolls in addition to those shown in Fig. 2 and providing the desired twist by rotation of the casings in which said rolls are mounted or by conventional means. The filamentary members of the second type may be used as yarn without other treatment, except as far as desired to provide further twist which can be accomplished by using a spindle of ordinary ring spinning construction (Fig. 13) which inserts twist, by subsequently twisting on conventional twister spindles, or by other means. J

Each group of folded filaments discharged from a set of bands 54 while having some unevenness in its folds is combined with other groups and the unevenness of one group tends to offset that of another group to give substantially uniform diameter in the combination. Added eifects may be providedin yarns composed of folded filaments by longitudinal pull resulting in a change in the angular relation between successive folded portions.

Fig. 15 illustrates a yarn from filamentary members of the first type of which 1 indicates the cut filaments and f indicates the continuous filaments. Fig. 16 illlustrates folded filaments shown untwisted for the sake of clearness, it beingunderstood that any desired twist may be given thereto. In this figure are illustrated more than six groups of folded filaments, which prodnot may be obtained by using each of the folding mechanisms heretofore described for simultaneously folding either several individual filaments or several groups of filaments. In the case of large filaments, such'filaments may be folded individually rather than folded in groups as specifically illustrated herein, such later procedure being particularly adapted for small filaments produced, the material used and other factors just as the process of textile spinning varies with each product. Coarser filaments may retain their separateness while passing around the first roller afterthe spinnerette (known in the trade as the godet) through the next set. of rollers which can overfeed them and may be folded individually. In any given case, the ideal is approached by having-the fewest possible number of filaments in each group being folded (one filament being the optimum), by using as few separate sets of rollers as possible at each stage and keeping the filaments or groups to be folded separate for that purpose by other means than separate rollers. To produce the simple embodiment of folded yarn, earlier referred to, the filaments after passing the godet l3 of Fig. 1 would be overfed by the next set of rollers into gathering or folding rollers mounted in a casing similarly to the rollers in casings 3| and 62, means being provided to oscillate or rotate such casing and no further apparatus would be required. A special case would be cutting all filaments at the same point; In the case of smaller pieces the Either of the two types of filamentary members may be utilized in the production of yarn withsame could be left untwisted to stagger or even same by scattering,

The invention of folding or cutting and combining filaments as described may be practiced using crimped filaments, thick and thin filaments, or filaments with protrusions made in accordance with the disclosure in my application 164,108, filed September 16, 1937, now Patent No. 2,200,946. The spirit of the invention will not be deviated from by using the processes described to make yarns fancy or special. While condi-- tions will vary with the nature'of material spun and. with denier, it will generally be found desirable to use a sizing to keep the folds compact during the process.

I am also aware where it has been specified that casings (such as 62) may be rotated, that the twist originated thereby will affect the yarn above and below the casing. Where such twist above the casing is not eliminated by cutting above the casing as in Fig. 2, or by rotating the mechanisms above the casing including the spinnerette, a cumbersome solution impractical in most cases, the twist will eventually cause the yarn above the casing to break. Such breakage will not prevent the continuous manufacture of some products described, e. g., folded filaments surrounded by continuous filaments, as long as the broken end finds its proper take-up roller after breakage. This is the result of such factors as proper arrangement .of rollers and air currents.

Reference is made to my co-pending application No. 164,108, covering methods of making filaments with protrusions, and the product resulting therefrom, particularly the formation of protrusions on filaments by spraying .film-formingsolution thereon. The methods of making filaments with protrusions mentioned in said application may be used in connection with the methods in this application, and'the resulting product will comprise filaments with protrusions.

I claim 1. As a new article of manufacture, yarn consisting of groups of artificial filaments folded to form overlapping sections in offset relation to each other to average out the unevenness of said sections and unfolded continuous artificial filaments combined therewith.

2. As a new article of manufacture, yarn containing a plurality of folded artificial filamentary elements, wherein the folds of one element offset the folds of another to average out the unevenness of said folds.

3. The method of forming yarns which comprises feeding groups of artificial 'filaments, continuously forming folds in all the filaments of each group, twisting each group of filaments about an axis parallel to the direction of the yarn, and consolidating said twisted groups of folded filaments.

4. The method of forming yarn which comprises feeding a group of artificial filaments, continuously forming folds in all the filaments of said group, twisting said group of filaments about an axis parallel to the direction of the yarn, and subsequently applying draft to said filaments.

5. The method of producing yarn which comprises feeding artificial filament to a compressing device at a higher rate than the linear speed of the compressing'device, thereby forming loops which the compressing device forms into folds, and twisting said folded filament about an axis parallel to the direction of the yarn, whereby to firmly incorporate the folds of the filament within the product.

6. The method of producing yarn whiclncomprises feeding coagulated artificial filaments from a spinnerette into a folding device and combining the folded filaments into yarns with the folds of one filament offsetting the folds of another to average out the unevenness of said folds to provide substantial uniformity in the yarn.

[Apparatus of the character described comprising a rotatable holder, a pair of rollers in said holder rotatable about axes perpendicular to the holder axis, means to feed filament to said rollers at a higher rate than their peripheral Y speed, guide means eccentric of the holder axis for laying said filament on said rollers in loop form, and means associated with said rollers for twisting said filament about an axis parallel to the rotational axis of said holder.

8. As a new article of manufacture, yarn containing a plurality of folded artificial filamentary elements and continuous artificial filaments combined therewith, wherein the folds of one element offset the folds of another to average out the unevenness of said folds.

GODFREY BLOCH. 

